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1. Understand and learn about automation control systems and types of automation control
systems.
2. Learn about the types of control system pneumatic control systems, hydraulic control systems
and electrical control system.
Specific Objectives;
At the end of this chapter, student should be able to:
1.
2.
3.
4.
5.
1.0
Introduction:
In todays fast-moving, highly competitive industrial world, a company must be flexible, cost
effective and efficient if it wishes to survive. In the process and manufacturing industries, this
has resulted in a great demand for industrial control systems/ automation in order to
streamline operations in terms of speed, reliablity and product output. Automation plays an
increasingly important role in the world economy and in daily experience.
Automation is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human
operators with machinery to assist them with the muscular requirements of work, automation
greatly decreases the need for human sensory and mental requirements as well.
What is Automation Control System?
Automation Control System - system that is able to control a process with minimal human
assistance or without manual and have the ability to initiate , adjust, action show or measures
the variables in the process and stop the process in order to obtain the desired output.
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1.
2.
3.
b)
1.1.2
Purpose
Ease of making changes / upgrade
Maintenance
Capability
Speed
Economy efficiency
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FIXED
AUTOMATION
FLEXIBLE
AUTOMATION
Specific
Variety
Difficult
Easy
Hard
Easy
Depends on
manufacturing and
design
Very high
Slow
Fast
Suitable for
all types of systems
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Example :
Fixed Automation
S1
S2
lamp
Vs
bB
Programmed Automation:
S1
S2
0000
0
0000
1
PROGRAMM
1000
0
LD
00000
AND
00001
OUT
10000
END (01)
PLC
I
N
P
U
T
O
U
T
P
U
T
LAMP
S1
S2
COM
COM
Vs
Vs
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Lamp
Vs
Lamp
u
PLC
Vs
Vs
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ii.
iii.
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Unemployment rate increases due to machines replacing humans and putting those
humans out of their jobs.
Technical Limitation: Current technology is unable to automate all the desired tasks.
Security Threats/Vulnerability: An automated system may have limited level of
intelligence, hence it is most likely susceptible to commit error.
Unpredictable development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
High initial cost: The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product, although the cost of
automation is spread in many product batches of things
TUTORIAL QUESTION:
Give definition of Automation Control System? [3m]
Make a comparison between Fixed Automation and Flexible Automation Control
System.[12m]
State three (3) types of control system which based on supply source and states the
differences between them.[12m]
Sketch an automatic control system diagram for:
a) Hydraulic Control System
b) Electric Control System
c) Pneumatic Control System
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The relay's switch connections are usually labelled COM, NC and NO:
COM = Common, always connect to this, it is the moving part of the switch.
NC = Normally Closed, COM is connected to this when the relay coil is off.
NO = Normally Open, COM is connected to this when the relay coil is on.
Connect to COM and NO if you want the switched circuit to be on when the relay coil
is on.
Connect to COM and NC if you want the switched circuit to be on when the relay coil
is off.
Relays
The actual relay building diagram
A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron
core , an iron yoke which provides a low reluctance path for magnetic flux, a movable iron
armature, and one or more sets of contacts. The armature is hinged to the yoke and
mechanically linked to one or more sets of moving contacts. It is held in place by a spring so
that when the relay is de-energized there is an air gap in the magnetic circuit.
When an electric current is passed through the coil it generates a magnetic field that
activates the armature, and the consequent movement of the movable contact(s) either
makes or breaks (depending upon construction) a connection with a fixed contact.
If the set of contacts was closed when the relay was de-energized, then the movement
opens the contacts and breaks the connection, and vice versa if the contacts were open.
When the current to the coil is switched off, the armature is returned by a force,
approximately half as strong as the magnetic force, to its relaxed position. Usually this force is
provided by a spring, but gravity is also used commonly in industrial motor starters. Most
relays are manufactured to operate quickly. In a low-voltage application this reduces noise; in
a high voltage or current application it reduces arcing.
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Operating Principle:
This circuit can be used to control traffic in public places, or to demonstrate traffic
rules in traffic-parks.
IC2, which is heart of the circuit, is a decade counter. In this counter for every pulse
fed to pin-14, potential keeps shifting from D1 to D9 in cyclic order.
IC1 is used as a pulse generator and generates pulses in regular configurable
intervals. These intervals can be changed by varying VR1.
The circuit is designed in such a way that out of nine pulses, relay RL1 remains
triggered for 4 pulses, relay RL2 for 1 pulse and relay RL3 for remaining 4 pulses.
Since D1-D4 provide current to T1, T1 is on whenever there is potential on any diode
D1 to D4, which keeps relay RL1 triggered. Similarly other diodes are responsible for
RL2 and RL3 triggering.
Red, Yellow and Green lamps can be connected to the relays RL1, RL2 and RL3
respectively to complete your mini traffic light controller.
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1.2.2 Contactors
d) Definition Contactor
A relay that can handle the high power required (higher current rating) to directly
control an electric motor or other loads is called a contactor.
A contactor is an electrically controlled switch used for switching a power circuit, similar
to a relay except with higher current ratings.
Contactors are used to control electric motors, lighting, heating, capacitor banks, and
other electrical loads.
b) Basic Component Of Contactor:
A contactor has three components. The contacts are the current carrying part of the
contactor. This includes power contacts, auxiliary contacts, and contact springs. The
electromagnet provides the driving force to close the contacts. The enclosure is a frame
housing the contact and the electromagnet.
Contactor
A basic contactor will have a coil input (which may be driven by either an AC or DC
supply depending on the contactor design). The coil may be energized at the same voltage as
the motor, or may be separately controlled with a lower coil voltage better suited to control
by programmable controllers and lower-voltage pilot devices.
c)
Operating Principle
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normally open contacts. Unlike relays, contactors are designed with features to control and
suppress the arc produced when interrupting heavy motor currents.
When current passes through the electromagnet, a magnetic field is produced, which
attracts the moving core of the contactor. The electromagnet coil draws more current initially,
until its inductance increases when the metal core enters the coil. The moving contact is
propelled by the moving core; the force developed by the electromagnet holds the moving
and fixed contacts together. When the contactor coil is de-energized, gravity or a spring
returns the electromagnet core to its initial position and opens the contacts.
i.
Main Contact.
Main contact of the contactor are normaly open contact and usually use to connect power
load to the main supply.
ii.
Auxiliary Contacts
Auxiliary contacts are secondary switching devices which work in conjunction with primary
switching equipment such as circuit breakers, relays, and contactors. These contacts are
physically linked to the main switching mechanism and activate at the same time it does.
Auxiliary contacts are commonly used as interlocks or retainers on the primary device's
control circuit and often used to give indication of its state of operation such as trip function
indication, electrical interlocks, and start circuit retainers.. Many contactors and circuit
breakers feature sets of auxiliary contacts as integral parts or they may be modular snap on
units which can be added or removed as required. Auxiliary contacts are available with either
normally open or normally closed contact points or a combination of both.
d) Examples Application Of Contactor In Motor Control Sytem.
1. DOL Motor Starter
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1. Since a contactor is required for a higher load, a relay is always cheaper than a
contactor.
2. A relay is normally used in appliances below 5KW, while a contactor is preferred
when the appliance is heavier.
3. A relay is used only in control circuit while a contactor can be used in both control
and power circuits.
4. In general contactors are little slower than relays
5. Contactor is so designed that it can be repaired while it is not normally done in the
case of relays.
NOTES:
It should be noted that when installing contactors or relays that you always check the coil
ratings. They often have not got a default rating of 230volts, and only go bang once if they are
connected to the wrong voltage!
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Hydraulic
Electric
Using electricity as a
supply source
Easy installation
Complicated Installation
Simple system
Simple design
Widespread use
Unit 1.2
RELAY AND CONTACTOR
WHAT IS RELAY
A relay is an electrically operated switch.
Current flowing through the coil of the relay
creates a magnetic field which attracts a lever
and changes the switch contacts. The coil
current can be on or off so relays have two
switch positions and most have double throw
(changeover) switch contacts as shown in the
diagram.
Symbol of relay
Several design of relay are in used today, 3pin,4-pin,5-pin,6-pin, single switch or dual
switches
3
2
Types of Relays
Relays are usuallly SPDT (Single Pole Double
Throw) or DPDT (Double Pole Double Throw)
but they can have many more sets of switch
contacts.
Poles : the number of sets of contacts
Throw : The number of positions or
combinations (open or close) the contacts
have.
Types of relay..
This is a Single Pole Double
SPDT-Single Pole Double Throw Throw relay. Current will
flow between the movable
contact and one fixed
contact (NC) when the coil
is de-energized.
When the relay coil is
energized the current will
flow between the movable
contact and the alternate
fixed contact (NO).
Types of Relays
Relay application
Relay can be used for various regulating,
control and monitoring functions:
As interfaces between control circuits and load circuits
For signal multiplication
For separation of direct current and alternating current
circuits
For delaying, generating and converting signals and
For linking information.
Operating Principle:
This circuit can be used to control traffic in public places, or to
demonstrate traffic rules in traffic-parks.
IC2, which is heart of the circuit, is a decade counter. In this counter
for every pulse fed to pin-14, potential keeps shifting from D1 to D9 in
cyclic order.
IC1 is used as a pulse generator and generates pulses in regular
configurable intervals. These intervals can be changed by varying VR1.
The circuit is designed in such a way that out of nine pulses, relay RL1
remains triggered for 4 pulses, relay RL2 for 1 pulse and relay RL3 for
remaining 4 pulses. Since D1-D4 provide current to T1, T1 is on
whenever there is potential on any diode D1 to D4, which keeps relay
RL1 triggered. Similarly other diodes are responsible for RL2 and RL3
triggering.
Red, Yellow and Green lamps can be connected to the relays RL1, RL2
and RL3 respectively to complete your mini traffic light controller.
WHAT IS CONTACTOR
A contactor is an electrically
controlled switch used for
switching a power circuit,
similar to a relay except with
higher current ratings.
A contactor is controlled by a
circuit which has a much lower
power level than the switched
circuit.
Examples Application Of
Contactor
Examples Application Of
Contactor
Relay vs Contactor
RELAY
CONTACTOR
Cheaper
Expensive
INTRODUCTION TO PLC
INTRODUCTION
In this chapter , we will discussed about PLC in detail:
2.1 Definition of PLC
2.2 Define PLC Terminologies
2.3 Background PLC
2.3 The function of PLC and Types of Construction
2.4 Advantages of PLCs
2.1
Definition of PLC
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2.2
PLC Terminologies
sensors:
INTRODUCTION TO PLC
output devices/actuators:
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INTRODUCTION TO PLC
The CPU is a microprocessor that co-ordinates the activities of the PLC system. Its executes
the program, processes I/O signals & communicates with external devices
Ladder Diagram Ladder diagrams are specialized schematics commonly used to document industrial control
logic systems. They are called "ladder" diagrams because they resemble a ladder, with two
vertical rails (supply power) and as many "rungs" (horizontal lines) as there are control
circuits to represent built from relays, is being simulated
2.2
Background of PLC
Among the factors that create the initial design and development of control systems
that can be controlled are as follows:
i. Requirements of a low cost
ii. Intelligent system
iii. The Controller that is easy to control
The first PLC was designed by a team of engineers at the company General
Motors (GM), the United States in 1968 when the company is looking for other methods
to replace the complex system of relays. They also set the specifications of the new
control system must meet the following requirements:
i. Easily programmed
ii. There is no need for rewiring if there are changes on the program
iii. Smaller, cheaper and higher reliability.
iv. Simple building construction and the maintenance cost is cheap.
v. Cost competitive
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INTRODUCTION TO PLC
Function of PLC
Function
Sequence Control
Advanced Control
2.
3.
4.
5.
6.
Supervision control
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INTRODUCTION TO PLC
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CPU,
Memory
Input modules
Output modules
Power supply.
These components are integral to the PLC controller. Additionally the PLC has a connection
for the Programming and Monitoring Unit, Printer and Program Recorder.
3.1
Microprocessor
ROM
Operation
system
RAM
Programming
Data
Input
Unit/
Module
( CPU )
Output
Unit/
Module
Output
Unit
ADDRESS BUS
CONTROLLED BUS
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Updating inputs and outputs. This function allows a OLC to read the status of its
input terminals and energize or deenergize its output terminals.
Performing logic and arithmetic operations. A CPU conducts all the mathematic and
logic operations involved in a PLC.
Communicating with memory. The PLC programs and data are stored in memory.
When a PLC operating, its CPU may read or change the contents of memory
locations.
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Communicating with a programming terminal. The CPU transfers program and data
between itself and the programming terminal.
b) Memory Unit
Memory is the component that stores information, programs and data in a PLC. The
process of putting new information into a memory location is called writing. The
process of retrieving information from a memory location is called reading.
Above figure shows the memory unit in the internal design of PLCs. This unit contains
two (2) types of memory:
i.
ii.
Display and the indicator unit refers to the internal relay PLC status display. This can be seen
in the Console programming if the user using the mnemonic code and programming
computer screen if the user using software programming methods.
d)
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Referring to above figure, the input and output units are the units available in the internal
design of PLCs.
The Input/Output units are the interfaces between the internal PLC systems and the
external processes/ field devices to be monitored and controlled. Input Unit is the unit
which input devices (switches, sensors) are connected to it. While the output unit is a unit
which output devices (Lights, motors) are connected to it.
The main purpose of the I/O interface is to condition the various signals received from or
sent to the external input and output devices. Input modules converts signals from
discrete or analog input devices to logic levels acceptable to PLCs processor. Output
modules converts signal from the processor to levels capable of driving the connected
discrete or analog output devices.
Since the PLC is a logic based device with a typical operating voltage of 5 volts and the
external processes usually demand higher powers and currents, the I/O modules are
optically or otherwise isolated. The typical I/O operating voltages are 5V - 240 V dc (or ac)
and currents from 0.1A up to several amperes. The I/O modules are designed in this way to
minimize or eliminate the need for any intermediate circuitry between the PLC and the
process to be controlled.
Small PLC units would have around 40 I/O connections with larger ones having more than
128 with either local or remote connections and extensive upgrade capabilities.
3.2
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Tutorial :
ANSWER ALL THESE QUESTIONS
1.1 State THREE (3) units available in the microprocessor.
1.2 Explain the difference between RAM and ROM memory.
1.3 What do you understand about the Input Unit and Output Unit
1.4 Explain the functions of the printer unit.
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QUESTION
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